Solution Casting Dyed Optical Films for Eye Protection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional methods for manufacturing IR and visible coated lenses, such as extrusion and injection molding, face challenges including uneven coating on curved surfaces, dye degradation due to heat, susceptibility to scratches and chemicals, and increased thickness, which affects the effectiveness and aesthetics of eye protection.

Innovation Solution

The solution casting method is used to create functional films by dissolving polymers or PVA materials in solvents, adding dye solutions, and casting thin films without excessive heat, allowing for precise control and integration of IR and visible dyes directly into the polymer structure, resulting in a thin, durable, and optically pure film.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional extrusion or injection molding methods are used to add IR or visible dyes during the manufacturing process, then the lenses can be produced with protective coating, but heat is needed to soften the plastic films which causes dye degradation and reduces effectiveness of eye protection

Engineering Contradiction:

Improveeffectiveness of eye protectionVSAvoidheat exposure during manufacturing

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent changes the manufacturing parameters by using solution casting instead of extrusion or injection molding, allowing the process to proceed at lower temperatures that do not degrade the heat-sensitive dyes while still achieving the desired lens formation and protective coating application

Inventive Principle:

Principle #35Parameter changes

2Reliability

If traditional coating techniques like dipping or spraying are used to apply IR or visible dyes on curved lenses, then protective layers can be added, but the curvature of the lenses causes uneven coating application which reduces effectiveness of protection layers

Engineering Contradiction:

Improveeffectiveness of protection layersVSAvoiduniformity of coating application

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

Instead of applying coating to already-formed curved lenses (traditional approach), the patent inverts the process by first applying the dye solution to a flat substrate and then forming the lens curvature, ensuring uniform coating distribution before shaping

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The protective dye coating is applied in advance during the film formation process itself, rather than as a subsequent step, allowing the coating to be uniformly distributed throughout the material before the lens is shaped

Inventive Principle:

Principle #10Preliminary action

3Reliability

If additional protection layers are added on top of IR/visible layers to prevent scratches and chemical damage, then durability is improved, but the lens becomes thicker which creates a barrier for eyewear design and comfort

Engineering Contradiction:

Improveresistance to scratches and chemicalsVSAvoidlens thickness

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The patent combines multiple functions into a single integrated layer: the IR/visible protective dyes are incorporated directly into the lens material matrix during manufacturing, eliminating the need for separate protective coating layers while maintaining durability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The lens is manufactured as a composite material with the protective dye components uniformly distributed within the polymer matrix, creating an inherently durable material that does not require additional protective layers

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method produces films with maximum optical purity, low haze, excellent flatness, and dimensional stability, preventing dye degradation and reducing the need for additional protective layers, while maintaining optical clarity and durability.

Implementation Method 1

dissolving polymers or PVA materials in solvents, adding dye solutions

Methodology Applied

Scientific EffectDissolution: Solvation

Implementation Method 2

adding the dye solution to the polymer or PVA solution

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 3

casting thin films without excessive heat

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Implementation Method 4

letting the film dry and solidified

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 5

soluble dyes and/or metallic oxide pigments are used for coating to absorb or reflect light of certain frequencies, eg., IR frequencies, UV frequencies

Methodology Applied

Scientific EffectAbsorption of electromagnetic radiation: Absorption (EM radiation)

Implementation Method 6

Infrared is also harmful. Wireless communication, appliances, computer, and lights all emit different levels of harmful radiation

Methodology Applied

Scientific EffectInfrared radiation absorption: Infrared Radiation

Data Source

PatentUS10611106B2Methods and systems for making an optical functional film

Publication Date: 2020.04.07 HSU ROGER WEN YI

AI summary

A method to make dyed functional film comprising the steps of providing a soluble polymer material; adding an appropriate solvent to the polymer material to make a soluble polymer solution; providing a soluble dye; adding an appropriate solvent to the dye to make a soluble dye solution; adding the dye solution to the polymer or PVA solution, and introducing the dyed polymer or PVA solution to a solution casting device; removing a thin dyed functional film from the casting device; and letting the dyed functional film dry and solidified.